Multiple fault redundant motor

ABSTRACT

A device is presented having a first and a second motor control device. The first and the second motor control devices control rotation speed of a motor. The first or the second motor control devices continue to control rotation speed of the motor upon failure of either the first or the second motor control device. Also presented is a device having at least one motor. The at least one motor having at least one pair of bifilar windings. A further device is presented having at least one motor. The at least one motor having at least eight magnetic lobes. Another device is presented having a first motor connected to a shaft. A second motor is connected to the shaft. A fan hub is connected to the shaft. A fan blade is connected to the fan hub.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to enhancing a motor's life span, and moreparticularly to a multiple fault redundant motor.

[0003] 2. Description of the Related Art

[0004] As electronic devices, such as microprocessors, centralprocessing units (CPUs), servers, and other similar types of electroniccomponents become faster and are reduced in size, power consumed withinthe system per unit volume (power density) increases dramatically.Therefore, it is essential to dissipate the heat generated by electroniccomponents within the system during its operation to keep the electroniccomponents within their normal operating temperature ranges. If theelectronic components operate outside of their operating temperatureranges, the life span of the electronic components will be reduced orfail immediately.

[0005] One effective technique for dissipating the heat from electroniccomponents, such as a microprocessor, is to provide an internal fan, orfan assembly, to directly apply a relatively high-velocity air streamacross the surface of the electronic components. By forcinghigh-velocity air across the surface of the internal component(s), theconductive heat transfer coefficient for the surface of the internalelectronic components is increased, thus increasing the convectioncooling. Another technique of dissipating the heat from an electroniccomponent, such as a microprocessor CPU, is associating a heat sink withthe microprocessor CPU to increase the heat-dissipating surface area ofthe CPU for more effective cooling. These heat sinks have multipleheat-dissipating fins or elements at an upper surface. A lower surfaceof the heat sink is coupled to the electronic component and attachedwith a retention clip. Since the heat sink is comprised of metal ormetal alloys, the heat sink conducts heat away from the microprocessorCPU and allows convection cooling through the fins.

[0006] One method to achieve cooling on devices such as microprocessorsis to add additional fans by placing fans in parallel and in series. Aproblem with this method of cooling is that if one fan fails, theremaining fan must force air through an inoperable fan. Upon forcing airthrough an inoperable fan, fan speed must be increased, whichsignificantly increases noise and limits the types of fans that can beused. Single point failures often occur in motors, fans and mechanicaldevices. Many times, a bearing is the source of the single pointfailure. When a bearing fails in a fan, the motor or electronicssubsequently fail.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The invention is illustrated by way of example and not by way oflimitation in the figures of the accompanying drawings in which likereferences embodiment in this disclosure are not necessarily to the sameembodiment, and such references mean at least one.

[0008]FIG. 1 illustrates an embodiment including a multiple redundantfan with in-line redundant motors.

[0009]FIG. 2 illustrates an embodiment including a multiple redundantfan with opposing redundant motors.

[0010]FIG. 3 illustrates an embodiment having redundant electronics.

[0011]FIG. 4 illustrates an embodiment of the invention having redundantelectronics coupled to a single electrical attachment pad and a motorwith bifilar windings.

[0012]FIG. 5 illustrates one embodiment having redundant electronics andredundant magnetic lobes.

[0013]FIG. 6 illustrates an embodiment having redundant electronicscoupled to two electrical attachment pads.

[0014]FIG. 7 illustrates an embodiment having two independent motorscoupled in series.

[0015]FIG. 8 illustrates a collapsed view of the embodiment illustratedin FIG. 7.

[0016]FIG. 9 illustrates an embodiment having two separate counterrotating motors with shafts attached to a common hub.

[0017]FIG. 10 illustrates a collapsed view of the embodiment illustratedin FIG. 9.

[0018]FIG. 11 illustrates an embodiment having a redundant bearing.

[0019]FIG. 12 illustrates an embodiment having a triple redundantbearing.

[0020]FIG. 13 illustrates an embodiment having a dual redundant bearing.

[0021]FIG. 14 illustrates an embodiment of a dual redundant bearinghaving roller bearings.

[0022]FIG. 15 illustrates an embodiment having redundant sets ofbearings and a frangible link.

[0023]FIG. 16 illustrates an embodiment having a strain gauge to detectbearing failure.

[0024]FIG. 17A illustrates an embodiment having optical sensors todetect bearing failure.

[0025]FIG. 17B illustrates a bearing a having light hole.

[0026]FIG. 18A illustrates another embodiment used to detect bearingfailure.

[0027]FIG. 18B illustrates a bearing having a reflective surface marker.

[0028]FIG. 19A illustrates yet another embodiment that detects bearingfailure.

[0029]FIG. 19B illustrates a bearing having reflective markers coupledto one side of the bearing.

[0030]FIG. 20 illustrates an embodiment having a heat sink coupled to amultiple redundant fan.

DETAILED DESCRIPTION OF THE INVENTION

[0031] The invention generally relates to a method and apparatus for fanredundancy. Referring to the figures, exemplary embodiments of theinvention will now be described. The exemplary embodiments are providedto illustrate the invention and should not be construed as limiting thescope of the invention.

[0032]FIG. 1 illustrates an embodiment having a single fan with multipleredundant components. Fan 100 includes fan 110, fan hub 120, fan motors130 and 135, bearings 140 and housing 150. In one embodiment, fan 110contains three fan blades. One should note, however, that otherembodiments can vary the number of fan blades without diverging from thescope of the invention.

[0033]FIG. 2 illustrates an embodiment having multiple redundant fan200. Multiple redundant fan 200 includes fan housings 220 and 225, fanblades 210, motors 230 and 235, bearings 240 and fan hub 250. In thisembodiment, fan blades 210 include three fan blades. One should note,however, that fan blades 210 can include more or less fan blades withoutdiverging from the scope of invention.

[0034] The embodiments illustrated in FIGS. 1 and 2 will now bediscussed with reference to the various components. FIG. 3 illustratesan embodiment having motor and electronics 300. In this embodiment,electronics A 320 and electronics B 330 are electrically independentsets of electronics that are structured in a parallel circuit. Thewindings of motor 310 are electrically connected to both sets ofelectronics A 320 and electronics B 330. In one embodiment, motors 130and 135 (illustrated in FIG. 1) can each be replaced by motor 310. Inanother embodiment, motors 230 and 235 (illustrated in FIG. 2) can eachbe replaced by motor 310.

[0035] As illustrated in FIG. 3, motor 310 includes one set of windings.Both electronics A 320 and electronics B 330 include speed control formotor 310. Both electronics A 320 and electronics B 330 can use variousmeans for controlling motor speed, such as pulse width modulation (PWM),voltage/resistance variation, or thermal speed control. Also, bothelectronics A 320 and electronics B 330 can use a tachometer or similarmeans for fan rotation feedback.

[0036] Electronics A 320 and electronics B 330 can both work togethersimultaneously to control motor 310's rotational speed, or can each workindependently. In the case where electronics A 320 and electronics B 330run simultaneously, the control of motor 310 is “split” betweenelectronics A 320 and electronics B 330. In the case of failure ofeither electronics A 320 or electronics B 330, the non-failedelectronics will continue to control motor 310 to maintain fan speed. Inthe case where electronics A 320 and electronics B 330 do not controlmotor 310 simultaneously, upon a failure of either electronics A 320 orelectronics B 330, the non-failed electronics will take over and controlmotor 310. This can be accomplished with a simple switch, feedback andcontrol, voltage/current detection, etc. One should note that variousfan speed feedback means can be implemented with signals sent to eitherelectronics A 320 or electronics B 330 by means such as, tachometers,light sensors, etc.

[0037] By using redundant electronics (electronics A 320 and electronicsB 330) to control motor 310, motor 310 can continue to function in caseof one of the electronics failing. In the case where motor 310 is usedas a cooling fan for electronic components, the redundant electronicsovercome the signal point failure of having a single electronicscontroller for motor 310. Thus, cooling of electronic components can bemaintained, and acoustical noise can be limited by having a single fanblade component coupled to a redundant fan motor system (e.g., fan 100,illustrated in FIG. 1 or fan 200, illustrated in FIG. 2) when coupledwith an embodiment including electronics A 320 and electronics B 330.

[0038]FIG. 4 illustrates an embodiment having motor and electronics 400.In this embodiment, motor 410 includes bifilar windings (dual redundantwindings) coupled to a single electrical pad 420. One should note,however, that separate electrical pads can be coupled to motor 410 (aslong as the separate electrical pads are electrically coupled similarlyas to how pad 420 is coupled with the windings of motor 410, electronicsA 320 and electronics B 330).

[0039] In this embodiment, if either electronics A 320 or electronics B330, and either one of the bifilar windings fail, motor 410 continueswith normal operation. Electronics A 320 and electronics B 330 arecoupled in a parallel circuit structure. Also, the bifilar windings arestructured in a parallel. The bifilar windings are electrically coupledto both sets of electronics, thus achieving dual fault capability.

[0040]FIG. 5 illustrates an embodiment having motor and electronics 500.Motor and electronics 500 include electronics A 320, electronics B 330,first electrical pad 520, second electrical pad 510, and motor 530.Motor 530 includes two sets of independent windings on differentmagnetic lobes. Therefore, motor 530 includes two independent sets ofwinding each having four magnetic lobes. One should note, that typicalmotors (e.g., DC fan motors) only include four magnetic lobes. Each setof four magnetic lobes is coupled to an independent set of electronics(electronics A 320 and electronics B 330). Between electrical pad 510and electrical pad 520 there are two north and two south poles.Therefore, in this embodiment, motor 530 achieves redundancy viaelectronics and windings. If either set of electronics fail, and/oreither set of windings fail, motor 530 can continue to run with normaloperation.

[0041]FIG. 6 illustrates an embodiment having motor and electronics 600.Motor and electronics 600 include motor 610, first electrical pad 510,second electrical pad 520, electronics A 320 and electronics B 330.Motor 610 includes four magnetic lobes with bifilar (dual redundant)windings. Each set of windings are coupled to a set of independentelectronics (electronics A 320 and electronics B 330). In thisembodiment, redundancy is achieved via electronics and/or windings. Ifeither set of electronics or either set of windings fail, the motor willcontinue with normal operation.

[0042]FIG. 7 illustrates an embodiment having two independent motorscoupled in series. Fan 700 includes fan blades 710, fan hub 720, fanhousing 730, dual in-line motors in series 740 and shaft 750. In thisembodiment, if one of the motors in series 740 fails, the non-failedmotor can run fan 700 at full speed. Both in-line series motors 740rotate in the same direction.

[0043]FIG. 8 illustrates a collapsed view of fan 700 illustrated in FIG.7 (denoted 800 in FIG. 8). Fan 800 may have a thickness slightly greaterthan a fan having a single motor to accommodate the dual in-line seriesmotors 740. By having two motors in series, fan 800 reduces acousticalnoise, and saves space over two separately housed fans. Either of thetwo motors in this embodiment can be operate simultaneously orindependent. If either of the motors in this embodiment operatesindependently, feedback sensors can trigger control electronics toswitch to the other motor in series with the failed motor. In oneembodiment, in-line series motors 740 can run simultaneously whereinpower may be split between the two in-line series motors to achievenecessary fan speed. One should note that other redundancies can becombined with this embodiment, such as redundant electronics, electricalpads, magnetic lobes, windings, etc.

[0044]FIG. 9 illustrates an embodiment having two separate motors thatrotate in the opposite direction of each other and share a common shaft.Fan 900 includes a first housing 910, a second housing 920, fan blades930, fan hub 940, first motor 950, and second motor 960. First motor 950and second motor 960 can run simultaneously in the opposite rotationdirection over the common shaft or can run independently. In case of afailure of either motor 950 or motor 960, the non-failed motor willcontinue to rotate fan blades 930. In one embodiment, motor 950 andmotor 960 can each run simultaneously at a lower power that wouldnecessitate rotating fan blades 930. Upon failure in this case, thenon-failed motor will have its power increased to compensate for thefailed motor. By having two motors that run in the opposite rotationdirection from one another, not only is space saved by not using twoseparate fans for redundancy, but acoustical noise is reduced by thesingle fan blade dual motor system. Also, when two separate fans are runin series, if one fan fails, the non-failed fan needs to push airthrough the failed fan. To do this, the non-failed fan would need toincrease its fan speed. Thus, increasing acoustical noise. FIG. 10illustrates a collapsed view of fan 900. One should note that otherredundancies can be combined with this embodiment, such as redundantelectronics, electrical pads, magnetic lobes, windings, etc.

[0045] While the presented embodiments include redundant motors,electronics, windings and/or magnetic lobes, a device, such as a directcurrent (DC) fan, can still have a single point of failure that is apossibility. This single point of failure possibility is the bearing. Toovercome the single point failure possibility, one embodiment includesredundant bearings.

[0046]FIG. 11 illustrates an embodiment having a redundant bearing 1100.Redundant bearing 1100 includes outer sleeve 1110, inner sleeve 1120,inner bushing sleeve 1130 and bearing balls 1140. In this embodiment, ifthe ball bearing portion fails (i.e., 1110, 1120 and 1140) the sleevebearing (i.e., 1120 and 1130) will continue with normal operation.Therefore, redundancy in the bearing is achieved. One should note thatbearing balls 1140 can be replaced with other types of bearings, such asroller bearings, without diverging in scope.

[0047] When redundant bearing 1100 is used in one of the presentedembodiments having multiple redundancies, such as motors, electronics,windings and/or magnetic lobes, single point failures are overcome. Oneshould note that this embodiment can be used in other devices besides DCfans, such as alternating current (AC) motors, wheels, and other devicesrequiring rotation over a shaft. This embodiment can be made of variousmetal, metal-alloys, synthetic materials, such as hardened plastic, etc.Moreover, this embodiment can be size adjusted, depending on the deviceincorporating the bearing and size required due to load. Also, furtherredundancies, i.e., bearing sets, can be added if necessary for theapplication.

[0048] By having a redundant bearing incorporated within embodimentshaving redundant motors, fan reliability and component life areincreased by reducing single point failure possibilities. Also, devicesthat require fan cooling can achieve fan cooling redundancy with less ofa fan footprint. Moreover, acoustical noise can be reduced in devicesthat would typically have redundant fan systems by using embodimentshaving multiple redundancies, thus, reducing fan count withoutsacrificing fan cooling redundancy.

[0049]FIG. 12 illustrates an embodiment having a triple redundantbearing. Triple redundant bearing 1200 includes outer sleeve 1210,middle sleeve 1220, inner sleeve 1230, inner bushing sleeve 1240 andbearing balls 1250. One should note that bearing balls 1250 can bereplaced with other bearings means, such as roller bearings, withoutdiverging in scope. As can be seen in FIG. 12, this embodiment has threesets of races and two sets of ball bearings. In this embodiment, if oneset of ball bearings fail, the second set will continue with normaloperation. Further, if both sets of ball bearings fail, triple redundantbearing 1200 then acts as a standard bushing adding additional life tothe device using triple redundant bearing 1200. Also, it should be notedthat if any two of the redundancies fail, triple redundant bearing 1200still continues to perform as a normal bearing.

[0050] Triple redundant bearing 1200 can be used in various rotatingdevices, such as motors, various mechanical devices, wheels, etc. Thisembodiment can be made of various metal, metal-alloys, syntheticmaterials, such as hardened plastic, etc. Moreover, this embodiment canbe size adjusted, depending on the device incorporating the bearing andsize required based on load. Also, further redundancies, i.e., bearingsets, can be added if necessary for the application. When tripleredundant bearing 1200 is used in cooling fans, a typical single pointfailure of a typical bearing is overcome. Therefore, triple redundantbearing 1200 adds life to components needing cooling and to internal fancomponents, such as the electronics and windings of the fan motor. Thus,cooling redundancy can be achieved without necessitating separateredundant cooling fans. Therefore, it follows that acoustical noise isreduced by having triple redundant bearings incorporated into coolingfans by using a single fan with redundant bearings instead of usingmultiple separate fan devices for redundancy.

[0051]FIG. 13 illustrates an embodiment having a dual redundant bearing.Dual redundant bearing 1300 includes outer sleeve 1310, middle sleeve1320, inner bushing sleeve 1330, and bearing balls 1340. One should notethat other bearing means, such as roller bearings, can be used insteadof bearing balls 1340 without diverging in scope. In this embodiment,there are three sets of sleeves and two sets of ball bearings. If one ofthe ball bearing sets fails (e.g., seizes due to loss of lubrication,change of ball shape, etc.) the second set will continue with normaloperation. By using dual redundant bearing 1300, a device incorporatingbearing 1300 can extend its usefulness and/or life span.

[0052] Bearing 1300 can be used in various devices such as AC and DCmotors, various mechanical devices, wheels, etc. This embodiment can bemade of various metal, metal-alloys, synthetic materials, such ashardened plastic, etc. Moreover, this embodiment can be size adjusted,depending on the device incorporating the bearing and size requiredbased on load. Also, further redundancies, i.e., bearing sets, can beadded if necessary for the application. When this embodiment isincorporated in a device, such as a cooling fan, the bearing redundancyremoves the necessity for having separate cooling fans that are requiredfor redundancy protection. Also, acoustical noise level is reduced byeliminating separate redundant fan devices. By incorporating bearing1300 into multiple redundant fans (e.g., previously discussedembodiments) single-point failures due to a single bearing failure isovercome.

[0053] As noted above, roller bearings can be used instead of ballbearings in the embodiments illustrated in FIGS. 11, 12 and 13. Forexample, FIG. 14 illustrates the embodiment illustrated in FIG. 13 withthe ball bearings replaced with roller bearings 1410. Further, otherknown bearing means can be used in the place of balls or rollers withoutdiverging from the scope of the embodiments of the invention. Also notethat the embodiments illustrated in FIGS. 11, 12, 13 and 14 can be madewith various metal, metal alloys, ceramics, synthetic materials, such ashardened plastic, etc. Moreover, these embodiments can be size adjusted,depending on the device incorporating the bearing and required sizebased on load.

[0054]FIG. 15 illustrates an embodiment having redundant sets ofbearings and at least one frangible link. Frangible link 1510 (forexample purposes, two frangible links are illustrated in 1500) is addedto redundant bearing 1500 to achieve fail over operation rather thanparallel redundancy. By using one or more frangible links, control isachieved as to which of the bearing redundancies to use first within aredundant bearing. In this embodiment, a failed bearing will transfer animpulse force to frangible link 1510 due to torque from a shaft, thus,breaking frangible link 1510 and resulting in the spin-up of a redundantbearing. One or more frangible links 1510 can be incorporated with theembodiments illustrated in FIGS. 11-14.

[0055] Frangible link 1510 can be attached to a redundant bearing by anadhesive, such as epoxy, using a heat source, such as a weld, etc.Frangible link 1510 can be made from a metal, a metal alloy, a ceramicmaterial, synthetic material, such as a hardened plastic material, etc.Depending upon the use of a redundant bearing, such as redundant bearing1500, the tensile strength of frangible link 1510 is varied to effectefficient breaking of frangible link 1510 upon one of the redundantbearing sets failing (e.g., shaft torque due to seizing of a bearingbecause of loss of lubrication, etc.).

[0056]FIG. 16 illustrates an embodiment having at least one strain gaugeto detect if a bearing has failed. Device 1600 illustrated in FIG. 16includes main shaft 1610, strain gauges 1620, bearings 1640 and 1650,and shaft 1630. In this embodiment, at least a single strain gauge isused for each bearing coupled with main shaft 1610. Bearings 1640 and1650 are inserted into the main sleeve as illustrated in FIG. 16.Bearings 1640 and 1650 are made in such a way as to not slip afterplaced within the main sleeve.

[0057] In one embodiment, bearing 1640 and 1650 have their outer surfaceknurled to provide a non-slippable contact between bearing 1640 and1650, and the main sleeve. If one of the bearings fail (i.e., seizes,loses lubrication, deforms, etc.) shaft 1630 will have increasedfriction against a bearing set. As this friction increases, an increasein torque would be transferred from the shaft to the main sleeve throughthe failed bearing. Strain gauges 1620 measure the increase in torqueand detect if the shaft is rotating inside the bearing. Stain gauges1620 can output an electrical signal based on the measured variedresistance caused by strain in the device. The signal output from straingauges 1620 can be used to respond with an alert or event signal. Forexample, the output from strain gauges 1620 can be used to signal analarm and shut down the device whose bearing has been sensed to havefailed.

[0058] A process for detecting bearing failure for this embodiment is asfollows. Determine a nominal value from strain gauges 1620 during normaloperation. This can be simply collecting transmitted signals from straingauges 1620 for a set period of time. Determine a tolerance level for anallowable difference between the normal operation of bearing 1640 and1650 and a problem, such as additional friction caused from a failingbearing. With redundant bearings, a ratio of bearing sets to each othercan be determined. Therefore, a difference if any, between an output ofstrain gauges 1620 for each bearing set ran can be determined based onthe ratio. Transmit a signal from a strain gauges 1620 to a circuit orprocessor that will keep a running record of received signals forcomparison. Upon exceeding the allowable difference between normaloperation and a possible problem, transmit a warning signal to a user orcircuit. Alternatively, transmit a shutdown signal to a circuit,processor, or device 1600.

[0059] In one embodiment, bearing 1640 and 1650 are redundant bearings(i.e., bearings illustrated in FIGS. 11-15). In this embodiment, straingauges 1620 can sense the change in torque as redundancies fail, e.g.when one of the redundant bearing sets fail. This embodiment alsodetects when all the redundancies in bearings 1640 and 1650 fail. Inthis embodiment, output signals from strain gauge 1620 can be used totrigger warnings and to apprise a user or other device that a bearingmay soon fail. In response, the device using strain gauge detection canshut down the device before a component fails, such as over heatedelectronics, overheated motor windings, etc.

[0060] In one embodiment, device 1600 is used with a DC cooling fan(e.g., embodiments illustrated in FIGS. 1, 2, 7 and 9). In thisembodiment, besides having multiple redundancies (i.e., redundantelectronics, windings and/or magnetic lobes, motors and bearings).Device 1600 is incorporated to detect changes in torque along the shaftin order to warn of impending or complete bearing failure. In thisembodiment, the output signals from strain gauges 1620 can betransmitted to a device, such as processor, server, circuit, etc., and awarning signal can be transmitted to a user (s). Alternatively, theoutput signals from strain gauges 1620 can be transmitted to a devicesuch as processor, server, circuit, etc., and a shutdown procedures canbe initiated. For example, if it is known that a bearing has or soonwill fail (based on output signals from strain gauges 1620), a “soft”shut-down process can occur wherein a device or system can be broughtdown slowly without having components failing due to a “hard” shut down,or excessive heat buildup caused by a failing fan system.

[0061]FIG. 17A illustrates an embodiment using optical emitter/receiver(or optical emitter/sensor) devices to detect bearing failure. Device1700 includes emitter/receiver 1730, optical beams 1740(transmitted/received by emitter/receiver 1730), hub 1710, bearings1720, main sleeve 1755, shaft 1750, and printed circuit board (PCB)1760. Emitter/receiver 1730 can be receiver/sensors, such asphotoelectric sensors, low powered lasers, photoelectric emitters, etc.Emitter/receivers 1730 are coupled between each inner sleeve of bearing1720. The purpose of Emitter/receiver 1730 is to detect a change inangular velocity of an inner sleeve of bearing 1720.

[0062]FIG. 17B illustrates a redundant bearing having light hole 1770 inbearing sleeve 1780. When an optical emitter (emitter/receiver 1730)emits an optical beam, as bearing 1720 rotates about shaft 1750 aportion of the beam transmits through light hole 1770 and is received onthe opposite optical receiver 1740. When one of the redundant bearingsets in bearing 1720 fails, a change in angular velocity can be detectedby determining the difference in angular velocity based onreceiver/sensors 1730 sensing a change in the sensed light beam. Aprocessor or circuit compares the angular velocity for a set period(such as every two seconds, every ten seconds, etc.). If the angularvelocity between periods changes, and the processor senses that fanspeed has not changed (based on a set tolerance determined fromredundancy ratios, etc.), a warning signal can be transmitted to usersor other devices informing of bearing failure or possible bearingfailure about to occur. Alternatively, a soft shut down signal can beissued by the processor or circuit for which the device connected withdevice 1700 and/or any other connected devices can be shut down withoutharm to any electronic components.

[0063] A process for detecting bearing failure for this embodiment is asfollows. A light is emitted through light hole 1770 in a bearing 1720coupled with shaft 1750. The emitted light (light beams 1740) isreceived through light hole 1770 at emitter/receiver 1730.Emitter/receiver 1730 transmits signals based on the received light. Acircuit or processor determines if the bearing has a failure. Thefailure is detected by determining rotation rate of shaft 1750 and ofbearing 1720. The rotation rate of shaft 1750 is compared with therotation rate of bearing 1720. If there is no difference in rotationrate (i.e., the bearing is failed), or there is a slight difference(based on a normal known difference), a signal is transmitted from thecircuit/processor to a user or other circuit/processor. Alternatively, ashutdown signal can be transmitted to shutdown a device before harm isdone by improper cooling.

[0064] In the case where device 1700 is incorporated in one of theembodiments illustrated in FIGS. 1, 2, 7 and 9, by using thisembodiment, electronic components can be saved from overheating due to afailed bearing incorporated within a cooling fan. It should be notedthat bearings 1720 can be used in non-redundant bearings where a lighthole is placed on the outer or inner sleeve of a single bearing. In thiscase, as the bearing begins to fail, emitter/receiver 1730 can signal toa circuit or processor of the impending or complete bearing failure.

[0065]FIG. 18A illustrates device 1800 used to detect variations inangular velocity of inner sleeves on bearings. Device 1800 includes hub1840, bearings 1810, shaft 1820, sensor/emitter 1830, PCB 1860 and mainsleeve 1850. In this embodiment, a light pipe is inserted into shaft1820 to transmit an optical beam (illustrated as 1835) to bearings 1810.In this embodiment, a small opening is made into shaft 1820 within thediameter of bearings 1810. Through this opening, a light beam fromsensor/emitter 1840 can be transmitted/received at sensor/emitter 1830.

[0066]FIG. 18B illustrates bearings 1810 having reflective surfacemarker 1870 coupled with an inner sleeve of bearing 1810. Reflectivesurface marker 1870 can be a reflective coating on a small portion ofthe inner sleeve, be formed as part of the inner sleeve, or othertechnique to coupled reflective surface marker 1870 to the inner surfaceof the inner sleeve (the surface that couples bearing 1810 to shaft1820). Reflective surface marker 1870 can be any reflective marker, suchas a black stripe, a colored stripe (paint or adhesively applied),different metal-alloy from the inner bearing sleeve that is compatiblewith the inner bearing sleeve, photo activated marker (paint oradhesively applied), etc. As bearing 1810 rotates about shaft 1820sensor/emitter 1830 transmits an optical beam through the inserted lightpipe, which reflects off reflective surface marker 1870 as bearing 1810rotates. Upon bearing 1810 failing, angular velocity of the bearing willchange as compared to the shaft. The angular velocity sensed from thelight pipe to sensor/emitter 1830 is compared with a shaft tachometer(not shown). If there is a difference in angular velocity between theshaft and the reflective surface section sensed by sensor/ emitter 1830,a circuit or processor will transmit a signal indicating that thebearing 1810 is about to fail. Once it is known that bearing 1810 isabout to fail, a warning signal can be sent to users or devices.Alternatively, a shutdown sequence can be initiated. One should notethat bearing 1810 can be a non-redundant bearing or redundant bearing asillustrated in FIGS. 11-15.

[0067] A process for detecting bearing failure for this embodiment is asfollows. A light (light beam 1835) is emitted by sensor/emitter device1830 through a light pipe inserted through shaft 1820. Reflected lightis received after being reflected by reflective marker 1870 situated onbearing 1810. Signals are transmitted from sensor/emitter device 1830based on the received reflected light. It is then determined whether abearing failure has occurred. The detection of bearing failure is asfollows. Rotation rate of shaft 1820 and bearing 1810 is determined by acircuit or processor based on received signals from sensor/emitterdevice 1830. The rotation rate of shaft 1820 is compared with therotation rate of bearing 1810 by the circuit or processor. If there isany difference (based on a normal known difference), a signal istransmitted from the circuit/processor to a user, device or processor.Alternatively, a shutdown signal can be transmitted to shutdown a devicebefore harm is done by improper cooling.

[0068]FIG. 19A illustrates an embodiment that detects variations inangular velocity between a shaft and a bearing. Device 1900 includes hub1910, bearings 1920, shaft 1930, main sleeve 1940, PCB 1950 andsensor/emitters 1960. Bearings 1920 can be non-redundant bearings orredundant bearings such as those illustrated in FIGS. 11-15.

[0069]FIG. 19B illustrates bearings 1920. Bearings 1920 include areflective surface marker 1970 used to reflect light emitted bysensors/emitter 1960 and received back at sensor/emitter 1960.Reflective surface marker 1970 can be any reflective marker, such as ablack stripe, a colored stripe (paint or adhesively applied), differentmetal-alloy from the inner bearing sleeve that is compatible with theinner bearing sleeve, photo activated marker (paint or adhesivelyapplied), etc. Sensors/emitter s are placed such that beam 1965 istargeted at the reflective surface marker 1970. Bearings 1920 have anouter surface to prevent bearing 1920 to slip once coupled with mainsleeve 1940.

[0070] During normal operation, the inner race rate per minute (RPM)matches shaft 1930's RPM. If bearing 1920 fails or begins to fail, shaft1930 will begin to rotate inside the inner bearing race. Sensor/emitter1960 detects a change in RPM on the inner race. The difference in RPMbetween shaft 1930 and inner race 1975 of bearing 1920 is themeasurement of how effectively the bearing is working. Once a differencein RPM between shaft 1930 and bearing 1920 is detected by sensor/emitter1960 (coupled to a circuit or processor) a warning signal or shutdownsignal can be transmitted in order to prevent possible harm.

[0071] It should be noted, that a tachometer or similar device iscoupled to shaft 1930, wherein the RPMs of shaft 1930 are accumulatedand transmitted to a circuit or processor to determine a difference inRPM between the shaft and the inner race 1975. In one embodiment, device1900 is incorporated into a fan such as that illustrated in FIGS. 1, 2,7 and 9. In this embodiment, a fan tachometer is coupled with a fanspeed controller. The fan speed controller and sensor/emitter 1960coupled with a processor or circuit that checks for a difference inRPMs. A small tolerance can be used as a threshold value, or adifference greater than zero can be used for a set period, such as every10 seconds, 20 seconds, etc.

[0072] A process for detecting bearing failure for this embodiment is asfollows. A light is emitted by sensor/emitter device 1960 on reflectivemarker 1970 located on a sleeve of bearing 1920. Reflected light isreceived after being reflected by reflective marker 1970 situated on thebearing sleeve. Signals are transmitted from sensor/emitter device 1960based on the received reflected light. It is then determined whether abearing failure has occurred. The detection of bearing failure is asfollows. Rotation rate of shaft 1930 and bearing 1920 is determined by acircuit or processor based on received signals from sensor/emitterdevice 1960. The rotation rate of shaft 1930 is compared with therotation rate of bearing 1920 by the circuit or processor. The rotationrate of shaft 1930 is determined by a tachometer coupled with shaft1930. Output signals from the tachometer are transmitted to the circuitor processor. If there is no difference in rotation rate (i.e., thebearing is failed), or there is a slight difference (based on a normalknown difference), a signal is transmitted from the circuit/processor toa user, device or processor. Alternatively, a shutdown signal can betransmitted to shutdown a device before harm is done by impropercooling.

[0073]FIG. 20 illustrates an embodiment having a heat sink coupled witha multiple redundant fan 2010. Device 2000 includes multiple redundantfan 2010, multiple redundant fan adapter 2020, and heat sink 2030.Multiple redundant fan 2010 can be a fan such as that illustrated inFIGS. 1, 2, 7 and 9. In this embodiment, heat sink 2030 is also coupledwith a processor (or multi-processor) 2040. Multiple redundant fan 2010can operate at low RPMs since it is used to bring in fresh airover/through heat sink 2030.

[0074] In one embodiment, multiple redundant fan 2010 and heat sink 2030is attached to a multi-processor 2040 that resides in a server system.In this embodiment, due to the redundancy of fan 2010, less maintenanceis required due to the redundancies. Further, acoustical noise isreduced since a reduced number of fans are needed to maintain coolingredundancy. Further, less space is required to house a server or systemneeding cooling redundancy. Moreover, electromagnetic interference (EMI)containment is increased by having reduced apertures for cooling inserver chassis.

[0075] While certain exemplary embodiments have been described and shownin the accompanying drawings, it is to be understood that suchembodiments are merely illustrative of and not restrictive on the broadinvention, and that this invention not be limited to the specificconstructions and arrangements shown and described, since various othermodifications may occur to those ordinarily skilled in the art.

What is claimed is:
 1. An apparatus comprising: a first and a secondmotor control device, the first and the second motor control devicescontrol rotation speed of a motor, wherein one of the first and thesecond motor control devices continue to control rotation speed of themotor upon failure of one of the first and the second motor controldevices.
 2. The apparatus of claim 1, wherein the first and the secondmotor control devices operate simultaneously.
 3. The apparatus of claim1, wherein the first and the second motor control devices operateindependently.
 4. The apparatus of claim 1, wherein control of the motoris switched from one of the first motor control device and the secondmotor control device upon failure of one of the first motor controldevice and the second motor control device.
 5. An apparatus comprising:at least one motor, wherein the at least one motor having at least onepair of bifilar windings.
 6. The apparatus of claim 5, furthercomprising: at least one electrical pad coupled to the at least one pairof bifilar windings, and at least one motor control device coupled tothe at least one electrical pad.
 7. The apparatus of claim 5, furthercomprising: at least two electrical pads coupled to the at least onepair of bifilar windings, and at least two motor control devices coupledin parallel to each of the at least two electrical pads.
 8. Theapparatus of claim 7, wherein the at least two motor control devicesoperate simultaneously.
 9. The apparatus of claim 7, wherein the atleast two motor control devices operate independently.
 10. An apparatuscomprising: at least one motor, wherein the at least one motor having atleast eight magnetic lobes.
 11. The apparatus of claim 10, furthercomprising: at least one electrical pad coupled to the at least eightmagnetic lobes, and at least one motor control device coupled to the atleast one electrical pad.
 12. The apparatus of claim 10, furthercomprising: at least two electrical pads coupled to the at least eightmagnetic lobes, and at least two motor control devices coupled inparallel to each of the at least two electrical pads.
 13. The apparatusof claim 12, wherein the at least two motor control devices operatesimultaneously.
 14. The apparatus of claim 12, wherein the at least twomotor control devices operate independently.
 15. An apparatuscomprising: a first motor coupled to a shaft and a fan hub, a fan bladecoupled to the fan hub, and a second motor coupled to the shaft.
 16. Theapparatus of claim 15, further comprising: a first housing sectioncoupled to the first motor, and a second housing section coupled to thesecond motor, wherein the first housing section and the second housingsection form a single fan enclosure.
 17. The apparatus of claim 15,wherein the first motor and the second motor are positioned oppositely.18. The apparatus of claim 17, wherein the first motor and the secondmotor rotate in opposite directions to each other.
 19. The apparatus ofclaim 18, wherein the first motor and the second motor operatesimultaneously.
 20. The apparatus of claim 18, wherein the first motorand the second motor operate independently.
 21. An apparatus comprising:a first motor coupled to a shaft, a second motor coupled to the shaft, afan hub coupled to the shaft, and a fan blade coupled to the fan hub.22. The apparatus of claim 21, further comprising: a housing coupled tothe first motor and the second motor, and wherein the housing forms asingle fan enclosure.
 23. The apparatus of claim 21, wherein the firstmotor and the second motor are positioned serially.
 24. The apparatus ofclaim 23, wherein the first motor and the second motor rotate in thesame direction.
 25. The apparatus of claim 21, wherein the first motorand the second motor operate simultaneously.
 26. The apparatus of claim21, wherein the first motor and the second motor operate independently.